Xylem FLOJET R3521/03521 Series Operating and installation instructions

INSTALLATION & SERVICE INFORMATION
Pump Design: 3 chamber diaphragm
Motor Design: Permanent magnet DC
Voltages: 12, 24 VDC, 115 VAC
Pump Rating: IP 54 (splash proof)
Max. Amp. Draw: 12 VDC: 9 amps
24 VDC: 6 amps
115 VAC: 3 amps
Pump Head: Polypropylene
Elastomers:
Diaphragm Geolast, SantopreneTM
Check valves EPDM, Viton®
Max. Flow Rate: 4 GPM (15.1 LPM)
Max. Pressure: 60 psi (4.1 bar) switch cutoff
50 psi (3.4 bar) max running pressure
Liquid Temp: 40° F (4° C) Min*
140° F (60° C) Max*
Duty Cycle: Intermittent**
Weight: 5.05 lbs ( 2.29 kg) max.
Wiring Options: Standard 18 AWG leads
Plug-in Ports: 1/2” (12.7 mm)
SPECIFICATIONS
FLOJET Triplex High Flow Series pumps are designed for a wide
range of applications and are constructed from a selection of
materials suitable for handling a broad range of chemicals. The
Triplex High Flow pumps are self-priming and can run dry
without harm. They are intended for intermittent duty cycles but
can be run continuously for a short periods of time. The higher
the duty cycle, the shorter the expected life of the pump. Typical
uses include transfer, delivery, spraying, cooling, filtration,
dispensing, and pressure boosting.
Models equipped with an external bypass system are designed
to pump at high pressures while at low or high flow rates. Models
equiped with bypass only must be turned off/on manually, or by
an independent control device. Models equipped with a bypass
only will continue to run until the power is manually turned off.
The Triplex High Pressure pumps are not recommended for
continuous duty service due to limited motor brush life.
Operation at lower pressures and temperatures, however, will
extend overall pump service life.
BYPASS OPERATION (if equipped)
Pump models fitted with a pressure switch are known as
demand pumps. The pressure switch is preset to shut off the
pump motor automatically when a specific pressure is reached,
such as in closed discharge conditions. The pressure switch
turns the pump motor on automatically as the pressure drops,
such as when the discharge is opened. Demand operation is
considered an “intermittent duty” application. The maximum
intermittent duty cycle is that which will cause the motor to
reach its maximum thermal limits. Once the maximum thermal
limit is reached, the motor must be allowed to settle to a lower
(ideally ambient) temperature, before resuming operation.
Running the pump at or near the maximum thermal limit for an
extended period of time will shorten the life of the pump and
may result in immediate pump failure. Demand pump models
feature an integral pressure switch that automatically turns the
pump off/on in response to open/closed discharge conditions.
DEMAND OPERATION (intermittent duty)
Allow pump to prime with discharge line (or spray valve) open, to
avoid airlock. Built-in pressure switch will shut off pump
automatically when discharge valve is closed and will restart
pump when valve is opened. When pump runs out of liquid, it
will continue to operate. Running dry will not damage the pump.
Turn off manually.
OPERATION
* Consult factory for higher fluid temperature options
**
***
C
Consult factory for other type of port fittings
onsult factory for continuous duty application
Model R3521 / 03521 Series
High Flow Triplex Pump

DIMENSIONAL DRAWINGS - inches (mm)
For best performance, flexible hose is recommended instead of
rigid piping at the pump. Flojet Triplex 3521 Series ports are a
push-in type retained by a “C” clip. To install the required ports
move “C” clip forward to front of pump. Do not install pump
such that plumbing causes excessive stress on either port.
It is essential that a 20 mesh (min.) strainer or filter be installed
in the tank or in the pump inlet line to keep large foreign
particles out of the system. The use of check valves in the
plumbing system may interfere with the priming ability of the
pump. Check valves, if used, must have cracking (opening)
pressure of no more than 2 PSI.
PLUMBING
DO NOT USE TO PUMP FLAMMABLE FLUIDS, GASOLINE, KEROSENE, OR ANY FUEL OIL
DO NOT USE PUMP IN AN EXPLOSIVE ENVIRONMENT
MOUNTING
FLOJET Triplex 3521 Series pumps are self-priming. They may
be located several feet from the tank, above or below the liquid
level (they are not submersible pumps).
Risk of an electrical shock!
Suggested wiring information is given as a reference only.
STEP 1
Determine the distance from the power source to the pump
and then double the measurement. Wire gauge installation is
determined on the entire run length, to the pump and back.
STEP 2
Connect to power supply lead (red (+)) to the positive (+)
terminal on the battery or through a properly installed
fuse/circuit breaker panel. Then run the length of wire to the
pump, connecting the red wire through a switch appropriately
rated to the pump’s current requirements.
STEP 3
Route the wire so as not to create hazards in operation of the
engine, movement of steering components or human traffic.
STEP 4
Connect the red lead to the red/orange lead on the pump.
STEP 5
Connect the black lead from the pump to the ground or
negative power side (-) of the vessel.
STEP 6
Turn the system off when not in use for extended periods of
time or when the water supply tank is empty.
STEP 7
After installation, check voltage at the pump motor.
Voltage should be checked when pump is operating. Full
voltage must be available at the pump motor at all times for
proper pump operation and pump motor life.
WIRING
IF YOU ARE NOT FAMILIAR WITH
APPLICABLE ELECTRICAL STANDARDS,
HAVE THE UNIT INSTALLED BY A
QUALIFIED ELECTRICIAN
HEAD-FLOW CURVE (12 & 24 VDC)
FLOW RATE GPM (LPM)
AMPS (A)
HEAD - PSI (bar)
amp
flow
WARNING
2.18
(55)
3.19
(81)
4.30
(109) 3.98
(101)
8.50
(216)
2.25
(57)
3.93
(100)

Pressure Switch Assembly
1. Install the switch diaphragm into upper housing (6).
Note: Check the old diaphragm for the material mark located
in the center of the new diaphragms. V is for VITON, and E
is for EPDM. Select the correct material for the installation.
2. Install the switch body over the diaphragm, align the screw
holes and install the two mounting screws.
3.
Reinstall the two wires onto the spade connectors, then install
the switch cover and screw.
Check Valve Assembly
4. Install the o-ring into the o-ring groove located on the
discharge side of the check valve chamber assembly (3).
5. Install the check valve chamber assembly into the
diaphragm, thus aligning the check valve chamber with the
diaphragm seal walls (push in to secure to the diaphragm).
Upper Housing Assembly
6. With the check valve chamber sub assembly (3,4) installed
on the diaphragm, place the upper housing assembly (6)
onto the pre-assembled lower housing sub assembly (3,4).
7. Align the cam with the motor "D" shaft and motor list, then
slide the cam onto the motor shaft (lube the motor shaft
with a small amount of light grease).
8. Check the discharge location (see arrow on front of port) for
correct port orientation (discharge right is the standard posi-
tion).
9. Install the six pump head screws (7,8) through the upper
housing (6), 3 screws (8) will engage to lower housing (4).
The other 3 screws (7) will go through the lower housing (5)
into the front end bell assembly aligning the three pins on
the front end bell with the 3 holes on the lower housing and
tighten securely.
Motor Assembly
10. Install the pump head by following steps 6 through 9.
EXPLODED VIEW DRAWING
Pump Housing
(For numbers, refer to exploded view)
1. Disconnect power to the pump motor (5).
2. Remove the pressure switch cover (1) and remove the two
wire leads from the switch spade connectors.
3. Remove the six screws from the upper housing (7,8).
4. Remove the upper housing (6) from the check valve and
diaphragm/lower housing assemblies (3,4).
Check Valve Assembly
(To replace check valve only follow steps 1 through 6)
5. The check valve chamber and o-ring are located on the
diaphragm/lower housing assembly (3,4).
6. Remove the check valve chamber subassembly (3) from
the diaphragm/lower housing subassembly (pull the valve
chamber from the diaphragm) (3,4).
Diaphragm/Cam/Lower Housing Assembly
7. Remove the diaphragm/lower housing assembly (3,4) from
the motor front end bell adapter.
Motor Replacement
8. To replace the motor only, follow steps 1 and 2, then
disconnect 3 screws (7), and pull the pump head out.
Replace the motor with washer and gasket (9).
DISASSEMBLE REASSEMBLE
ITEM DESCRIPTION QUANTITY PART NUMBER
1 Pressure Switch 1 02091060
2 Valve chamber 1 20407021
3 Pump Head 1 21048-515A
4 Motor 112 VDC 02009-187
124 VDC R2019-080
1115 VAC 02029-174
5 Base Plate w/Grommets 1 11028-101
1 2
5
3 4

PUMP TROUBLESHOOTING CHART
Failure to prime - motor operates, but no pump discharge
• Restricted intake or discharge line. Open all line valves,
check for “jammed” check valves, and clean clogged lines.
• Air leak in intake line.
• Punctured pump diaphragm.
• Defective pump check valves.
• Crack in pump housing.
• Debris in check valves.
• Missing or damaged o-ring of control valve chamber.
• Pinched/kinked hose.
• Damaged
Motor fails to turn on
• Pump or equipment not plugged in electrically.
• Loose wiring connection.
• Pressure switch failure.
•Defective motor or rectier.
• Frozen cam/bearing.
AVAILABLE MODELS
Visit www.ojet.com for a complete list models numbers.
PREVENTIVE MAINTENANCE TIPS
If pumping a liquid other than water, the pump should be
ushed with water (if applicable) after each use. Sealers acting
as a lubricant can cause cracked housings or stripped threads
due to over-tightening. Care should be used when applying
sealers; the tape may enter the pump, thus inhibiting valve ac-
tion and causing no prime or no shut-off conditions. Failures
due to foreign debris are not covered under warranty.
Before freezing conditions occur, the pump must be liquid free
or winterized with proper anti-freezing chemicals. If mount-
ing the pump in an outdoor environment, the pump should
be shielded from water, dust, sunlight, and washdown spray.
Do not assume chemical compatibility. If the uid is improper-
ly matched to the pump’s elastometers, the pump may fail to
prime, have low pressures, or the pressure switch may not shut
off. Contact your supplier for advice.
SERVICE KITS
Kits are readily available to repair standard Triplex High Pres-
sure Series pumps. To insure that the correct kits are received,
the model number and all name plate data must be included
with the order. Contact a FLOJET distributor to order the nec-
essary repair kits.
RETURN PROCEDURE
Prior to returning any product to FLOJET, call customer service
for an authorization number. This number must be written on
the outside of the shipping package. Place a note inside the
package with an explanation for return as well as the authoriza-
tion number. Include your name, address and phone number.
MSDS required.
PRODUCT WARRANTY
XYLEM LIMITED WARRANTY WARRANTS THIS PRODUCT TO BE FREE
OF DEFECTS AND WORKMANSHIP FOR A PERIOD OF 2 YEARS. THE
WARRANTY IS EXCLUSIVE AND IN LIEU OF ANY AND ALL OTHER EX-
PRESS OR IMPLIED WARRANTIES, GUARANTEES, CONDITIONS OR
TERMS OF WHATEVER NATURE RELATING TO THE GOODS PROVID-
ED HEREUNDER, INCLUDING WITHOUT LIMITATION ANY IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTIC-
ULAR PURPOSE, WHICH ARE HEREBY EXPRESSLY DISCLAIMED AND
EXCLUDED. EXCEPT AS OTHERWISE PROVIDED BY LAW, BUYER’S
EXCLUSIVE REMEDY AND SELLER’S AGGREGATE LIABILITY FOR
BREACH OF ANY OF THE FOREGOING WARRANTIES ARE LIMITED TO
REPAIRING OR REPLACING THE PRODUCT AND SHALL IN ALL CASES
BE LIMITED TO THE AMOUNT PAID BY THE BUYER HEREUNDER. IN
NO EVENT IS SELLER LIABLE FOR ANY OTHER FORM OF DAMAGES,
WHETHER DIRECT, INDIRECT, LIQUIDATED, INCIDENTAL, CONSE-
QUENTIAL, PUNITIVE, EXEMPLARY OR SPECIAL DAMAGES, INCLUD-
ING BUT NOT LIMITED TO LOSS OF PROFIT, LOSS OF ANTICIPATED
SAVINGS OR REVENUE, LOSS OF INCOME, LOSS OF BUSINESS, LOSS
OF PRODUCTION, LOSS OF OPPORTUNITY OR LOSS OF REPUTA-
TION. THIS WARRANTY IS ONLY A REPRESENTATION OF THE COM-
PLETE LIMITED WARRANTY. FOR A DETAILED EXPLANATION, PLEASE
VISIT US AT:
WWW.XYLEMFLOWCONTROL.COM/FLOJET-WARRANTY, CALL OUR
OFFICE NUMBER LISTED, OR WRITE A LETTER TO YOUR REGIONAL
OFFICE.
Pump fails to turn off after discharge valves are closed
• Depletion of available liquid supply.
• Punctured pump diaphragm.
• Discharge line leak.
• Defective pressure switch.
•Insufcient voltage to pump.
• Debris in check valves.
Low ow and pressure
•Defective check valves (most cases).
• Air leak at pump intake.
• Accumulation of debris inside pump and plumbing.
•Worn pump bearing (excessive noise).
• Punctured pump diaphragm.
•Defective rectier or motor.
•Insufcient voltage to pump.
Pulsating ow - pump cycling on and off
•Restricted pump delivery. Check discharge lines, ttings,
valves and spray nozzles for clogging or undersizing.
© 2015 Xylem Inc. All right reserved. Flojet is a trademark of Xylem Inc. or one of its subsidiaries.
81000-417 Rev. E 9/2015